Zorc Foundry: Digital Transformation in Manufacturing

Project Overview

Advanced Factory Process Configurator

Zorc Foundry is an advanced factory process configurator designed to streamline the melting and casting of iron in the manufacturing industry. This integrated system automates and manages the entire workflow, from preparing the melt to finishing the product, while providing real-time data and comprehensive material tracking.

With configurable BPMN processes (for each material or product, users can choose which process they need) and user-interactive tasks, Zorc Foundry enhances operational efficiency, quality control, and scalability for industrial foundries.

Industry challenges

Managing complex foundry processes efficiently was a significant challenge in the industry.

Foundries needed solutions for integrating and automating data across various systems to improve operational workflows. Real-time monitoring and control of processes were essential for maintaining production quality and efficiency.

Enhancing operational efficiency and reducing waste were critical goals for sustainable manufacturing practices. Accurate material tracking throughout the production cycle was necessary to ensure consistency and quality.

Additionally, offering flexibility and customization for different factory needs was vital to address the diverse requirements of foundries. Ensuring quality control and assurance at every stage of production was paramount to meet industry standards and client expectations.

Results and Achievements

Outcomes

Zorc Foundry achieved significant milestones in operational efficiency and market penetration. Initially deployed in 2 factories in China, the success led to an expansion into additional factories in Germany, now being used in more than 10 foundries.

BEFORE

Zorc Foundry began with pilot implementations in two factories in China.

Initial focus was on stabilizing the product, integrating automation, and refining the processes' capabilities.

AFTER

Expanded deployment to other factories in Germany and China.

Enhanced operational efficiency and material tracking, contributing to more sustainable production practices, and reduction in energy consumption and product defects.

Integration with other microservices.

BEFORE

Zorc Foundry began with pilot implementations in two factories in China.

Initial focus was on stabilizing the product, integrating automation, and refining the processes' capabilities.

AFTER

Problem

Client's challenge

The client faced several significant challenges in their traditional foundry operations. The primary issues included:

1. Complex and Inflexible processes
Traditional foundry processes were rigid and could not easily adapt to different types of materials or production needs.

2. Lock of real-time data
Without real-time data, monitoring and controlling the production process were challenging, leading to inefficiencies and increased risk of errors.

3. Inefficient material tracking
The absence of an effective material tracking system resulted in poor inventory management and potential quality control issues.

4. Integration difficulties
Existing systems did not integrate well with other technologies used in the foundry, causing disruptions in workflow and data management.

5. User adoption
Employees found traditional systems difficult to use, leading to a lack of engagement and suboptimal performance.

Solution

Proposed solution

Zorc Foundry provides an advanced, all-in-one factory process configurator designed to optimize the melting and casting workflow. Our solution addressed the client's challenges through the following features:

1. Configurable BPMN processes
We designed configurable processes that allowed the system to adapt to various production requirements and material types, providing the necessary flexibility in choosing the right process.

2. Real-time data integration
By incorporating real-time data capabilities, we enabled continuous monitoring and control of the production process, enhancing operational efficiency.

3. Comprehensive material tracking
Our solution included robust material tracking features, ensuring accurate inventory management and quality control.

4. Seamless system integration
We facilitated integration with other microservices and systems within the foundry, ensuring smooth and efficient operations.

5. User-friendly design
The interface was designed to be intuitive and easy to use, promoting better adoption and engagement among employees.

A laptop with a screen showcasing how to create a ticket inside the app.

Photo with BulkExchange's CTO that provided the testimonial

'The work performed by Linnify has completely satisfied all project requirements and pleased all stakeholders in the company with its quality and the efficiency of its delivery. Their team is organized and fully integrated into our team in order to work as efficiently as possible.'

Stefan Schmitt, Managing Director

You can read the full review here

Linnify's Involvement

Role in the project

Our role in the project was comprehensive, encompassing the development and deployment of the Zorc Foundry system.

We aimed to create a robust and user-friendly factory process configurator that could manage the intricate workflows of melting and casting iron.

Our responsibilities included:

1. Designing configurable foundry processes
We developed processes that could be tailored to the specific needs of each foundry, allowing for flexibility in handling different types of materials and production requirements.

2. Implementing real-time monitoring
Our team integrated real-time data capabilities to monitor the entire workflow, providing up-to-date information on the production process.

3. Material tracking and data managament
We ensured that the system could track materials accurately throughout the production cycle, maintaining comprehensive records for quality control and operational efficiency.

4. System and microservices integration
We enabled seamless interaction between Zorc Foundry and other systems within the foundry, ensuring smooth operations and data flow.

5. Task orchestrator creation
We developed a task orchestrator to manage user-interactive tasks, improving operational control and efficiency.

Application of expertise

We leveraged our expertise to create a stable system capable of handling thousands of values and measurements and interacting with other systems within the foundry.

Our knowledge of industrial automation and real-time data integration played a pivotal role in the project's success.

Services

• Product Development
• Web Development

• Backend Development

Photo with the product success manager that provided the testimonial

'Working for almost 4 years on the project gave me a broad overview of how a foundry works. I saw the app's growth and how each feature incrementally covered new areas, resulting in a full process where a raw material becomes a finished product. It is exciting to see how the app is used in a real foundry and how the interactions from the foundry are displayed on our monitoring dashboards.'

Vasile Coman, Tech Lead

Geographical Focus

Primary market

Industrial foundries engaged in the melting and casting of iron, seeking to optimize their production processes, enhance operational efficiency, and improve quality control through automation and real-time data integration. The primary markets they operate in are Germany and China.

A globe illustration highlighting North America.

Conclusion and Future Outlook

Zorc Foundry has successfully been implemented in more than 10 foundries. The project has led to significant improvements in operational efficiency, material tracking, and energy consumption, contributing to more sustainable production practices.

Learning and Growth

During this project, we accumulated extensive experience in developing robust solutions for complex problems and integrating multiple technologies to support the specific needs of the industry.

Our work on Zorc Foundry enhanced our ability to create scalable, efficient systems tailored to unique operational requirements.

We gained valuable insights into managing industrial workflows, real-time data integration, and quality control, which will inform our future projects and innovations.

A laptop with a screen showcasing the details of an RFP.

Capabilities

Industries

Company

Zorc Foundry